Installation Method for Non-Slip Sanitary Flooring

ABSTRACT

A method of installing flooring and resulting structure are disclosed. The method is particularly useful for sanitary nonslip (or slip resistant) applications such as kitchens. The method includes the steps of positioning a first sheet of polymer flooring material with an upwardly-facing step cut along one edge of the first sheet on a floor to be covered, and applying a second sheet of polymer flooring material with a complementary downwardly-facing step cut along one edge of the second sheet to the upwardly facing step cut of the first sheet and to the floor adjacent the first sheet while concurrently sealing or bonding the respective faces to one another in a step lap joint.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part application of pending U.S.application Ser. No. 11/456,747, filed Jul. 11, 2006, which is herebyincorporated by reference in its entirety.

BACKGROUND

The present invention relates to flooring materials and in particularrelates to joints in certain types of polymer-based flooring materialsthat are used in non-slip (or “non-skid” or “slip resistant”)applications, sanitary applications, and applications in which bothnon-slip and sanitary characteristics are desired or necessary.

Certain structural elements in commercial or other public establishmentsmust meet the requirements of various local, state or federal codes. Forexample, a restaurant is typically governed by local health andsanitation codes, and if it meets certain other criteria, may also besubject to state and federal health and safety requirements such theOccupational Health and Safety Act (29 U.S.C. § 651 et seq.) and relatedregulations such as (but not limited to) 29 CFR 1910.21-1910.30.

In most circumstances, a restaurant must be floored with a material thatcan be maintained at, or if necessary brought to, the highest sanitarystandards. Additionally, restaurant flooring, particularly kitchen (orother food handling and preparation areas), should be formed of amaterial that helps prevent workers from slipping when the floor is wetor otherwise soiled with food or food preparation materials.

The concurrent requirements for high standards of sanitation andnon-slip (non-skid) characteristics can be at odds with one another incertain structures. For example, some non-slip surfaces are prepared bymixing a polymer or paint with a solid (grit) material and applying thepolymer in a manner analogous to painting to produce a surface withembedded abrasive particles. Non-slip flooring is also often produced byforming a three-dimensional pattern in the flooring material itself.

Alternatively, surfaces intended for sanitary use are often preferablyas smooth as possible so that they can be easily cleaned on a frequentbasis and so that they avoid structural elements that can trap dirt orother undesired items that can contribute to unsanitary conditions.

Typical materials for commercial kitchen flooring (although certainlyapplicable to residential areas as well) have included wood, concrete orcement, and ceramic and non-ceramic tile. Each of these offers certainadvantages and disadvantages depending upon the particularcircumstances.

More recently, polymer materials have become favored for theseapplications. As in many other circumstances, polymers are (usually) lowin relative cost as compared to wood or ceramic tile, are widelyavailable and offer a range of desirable properties.

Some of these polymer materials are available in pre-cured form,typically liquids. They are then applied using brushes, rollers orsqueegee-type tools. Such pre-cured polymers can be applied to a widevariety of surfaces and because of their liquid form, need not be precutor otherwise dimension the cause they (like all liquids) simply take theshape of their container, which in this case is the floor.

As potential disadvantages, however, materials applied as liquidstypically require a finite drying time, may produce undesired (or evenregulated) solvent vapors, may not stick well to certain underlyingsurfaces and may require sophisticated priming or be limited to certainsurface materials.

Accordingly, other polymers are available in cured sheets that cansimply be positioned as desired all on a floor to be covered.

For example, certain vinyl (e.g. polyvinyl chloride or “PVC”) polymerscan be easily manufactured into sheets or rolls of relatively large size(e.g., one quarter inch thick sheets of five feet by eight feet or rollsof the equivalent width and much greater length). Such sheets canprovide cushioning surfaces (important to those who work on their feetfor extended periods of time), that can be easily cleaned and maintainedat the necessary sanitary standards, and that provide a greater grip inmany circumstances then materials such as wood or ceramic tile. Examplesof such material are set forth in U.S. Pat. Nos. 5,466,320 and 5,560,797among others and commercially available materials are sold under thePROTECT-ALL® trademark (Oscoda Plastics, Inc. Oscoda, Mich., USA).

Because the polymer is manufactured and transported in sheet form(whether as discrete stacked sheets or rolls), the sheets in turn mustbe fitted to the particular flooring application. This may requirecutting the sheets to fit particular floor designs and also connectingthe sheets to one another in a manner that—where required—preserves thesanitary surface. Stated differently, merely placing individual PVCsheets on a floor does not complete the necessary sanitary arrangementsbecause food can gather at the unsealed joints and in turn encourage thegrowth of unsanitary bacteria.

An appropriate joint should resist forces of tension, compression,shear, cleavage, and peel. These can be addressed through variousstructural arrangements, including joints with additional layers ofreinforcing material. In flooring applications, however, joints thatchange the otherwise (usually) level flooring may be unacceptable. Thus,simple overlapping joints create a bump as do tapered overlappingjoints, single or double strap joints, and tapered strap joints.Similarly, using profiles (i.e., additional structural pieces) to createthe joint may be acceptable for some purposes, but can create a slightbump that is unacceptable in other circumstances. For the same reasons,the types of reinforced and U-shaped joints that can be used to connectmetal sheeting in non-flooring applications are generally unacceptablefor kitchen or other sanitary flooring. In addition to the bumps thatthey create, the bends and three-dimensional structures that theyinclude can defines spaces that are hard to clean and that can provide aincubation point for bacteria.

Accordingly, when installing PVC flooring in a food service (kitchen)application, the individual sheets must are often welded to one anotherto form the joint. This is typically carried out by placing two sheetsin abutting relationship, cutting a V-shaped channel that removes aportion of each abutting sheet (e.g. with a router) and then welding thesheets together using a PVC rod or bead while applying heat.

Although this technique has satisfactory applications, it requires boththe routing and welding steps. Because the seams are abutting, they alsohave a tendency to separate or potentially fail, leading to some of thesafety and sanitary problems described above.

Accordingly, a need exists for improved methods of joining suchpolymer-based flooring in food service and related applications.

SUMMARY OF THE INVENTION

In one aspect the invention is a method of installing flooring that isparticularly useful for sanitary, non-slip applications such askitchens. In this aspect the method includes the steps of positioning afirst sheet of polymer flooring material with an upwardly-facing stepcut along one edge of the first sheet on a floor to be covered, andapplying a second sheet of polymer flooring material with acomplementary downwardly-facing step cut along one edge of the secondsheet to the upwardly facing step cut of the first sheet and to thefloor adjacent the first sheet while concurrently sealing the respectivefaces to one another in a step lap joint

In another aspect, the invention is a floor covering. In this aspect,the invention includes a first sheet of polymer material with at leastone step cut edge facing upwardly from the floor, a second sheet ofpolymer material with at least one step cut edge facing downwardlytowards the floor and immediately overlying the upwardly facing step cutof the first sheet, and a heat seal joining the upwardly-facing step cutto the downwardly-facing step cut and thereby joining the first andsecond sheets of polymer material together all on the floor.

In another aspect, the invention is a method of repairing a butt jointin polymer flooring materials. The method includes the steps of forminga step cut in polymer flooring on both adjacent sides of an existingbutt joint, and sealing a strap of polymer material into the step cutabove the remainder of the butt joint to produce a combination strap andstep lap joint to replace the butt joint.

In yet another aspect, the invention is a portion of flooring materialon a floor. The structure includes a first sheet of polymer flooringmaterial, a second sheet of polymer flooring material abutting the firstsheet along respective edges of each sheet, a partial butt joint betweenthe first and second sheets adjacent the floor, a channel, portions ofwhich extend into each of the first and second sheets above the partialbutt joint, a polymer strap positioned in the channel above the partialbutt joint, and a seal between and among the polymer strap, the firstsheet of polymer flooring material and the second sheet of polymerflooring material that forms a combined strap and lap joint between andamong the first sheet, the second sheet, and the strap.

The foregoing and other objects and advantages of the invention and themanner in which the same are accomplished will become clearer based onthe followed detailed description taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a prior art welded joint between two pieces of PVCflooring.

FIGS. 2A and 2B illustrate a lap joint according to the presentinvention.

FIG. 3 illustrates a second embodiment of a lap joint according to thepresent invention.

FIG. 4 is a cross-sectional view of a sheet of polymer flooring materialfor use in the present invention.

FIGS. 5 and 7 illustrate the method of the invention in context.

FIGS. 6A through 6D illustrate another embodiment of the invention thatcan be used to repair existing joints in polymer flooring.

FIGS. 8 and 9 illustrate tools for welding plastic that are exemplary ofthose used in the present invention.

FIGS. 10A and 10B illustrate yet another embodiment of a joint accordingto the present invention.

DETAILED DESCRIPTION

The invention is a method of joining non-slip (non-skid) polymer sheetflooring materials suitable for sanitary use in a manner that improvesthe quality of the resulting seam while minimizing the problems raisedby joints in general and welded joints in particular.

For background purposes, FIG. 1 illustrates a prior art joint broadlydesignated at 10. The joint is formed of respective portions 11 and 12of polymer flooring, typically PVC as described earlier. In order toproduce the joint 10, a router is used to cut enough material from eachof the sheets 11 and 12 to define the respective oblique surfaces 13 and14. A bead of welding material (usually, but not necessarily the samematerial as the flooring) indicated by the dotted circle 15 is appliedbetween the surfaces 13 and 14 and melted to form the joint 16.

FIGS. 2A and 2B illustrate a step lap joint according to the presentinvention. The step lap joint is formed between respective first andsecond portions 20 and 21 of the PVC material. Each of the pieces 20 and21 includes a cut portion that defines the respective vertical steprisers 22, 23 and the horizontal steps 24, 25.

When these pieces are brought together as illustrated in FIG. 2B theyform the step lap joint broadly designated at 26.

Accordingly, in one embodiment the invention can comprise the portion ofPVC flooring material illustrated at 7 in FIG. 4 that includes a pair ofsteps 30 and 31 on either edge, with the steps being oriented oppositeto one another with respect to the plane of the material 29 so thatmultiple pieces the same as the illustrated piece 27 can be easilyjoined to form the step lap joints illustrated in FIGS. 2A and 2B.

In its broadest aspects, the method comprises positioning a sheet 20 ofthermoplastic flooring material with an upwardly facing step cut 24 (orupwardly angled edge as discussed below) along one edge of the firstsheet 20 on a floor 19 (e.g., FIG. 5) to be covered and then applying asecond sheet 21 of thermoplastic polymer flooring material with acomplementary downwardly facing step cut 25 (or downwardly facing anglededge also as discussed below) along one edge of the second sheet 21 tothe upwardly facing step cut 24 of the first sheet 20 and to the floor19 adjacent the first sheet while concurrently forming a seal (or bond),usually by applying sufficient heat (or energy) to the respective stepfaces to melt (or bond) the polymer.

Polyvinyl chloride (PVC) is a widely used material for the respectivesheets 20 and 21, but it will be understood that other thermoplastic orthermosetting polymers can be used as desired or necessary. These termsare used in their well-understood sense; i.e. thermoplastic polymers arethose which will soften and melt under the application of heat whilestill retaining their basic chemical composition. Thermosetting polymerstend to undergo some type of chemical reaction—typicallycross-linking—under the application of heat. As a result, applyingmoderate heat to a thermoplastic polymer will cause it to soften, whileapplying heat to a thermosetting polymer will initially cure it (i.e.,the cross-linking reaction). When heat is thereafter applied to athermosetting polymer, it will not produce softening, but will instead(if sufficient heat is applied) heat the polymer until it burns ordegrades

In addition to PVC, exemplary thermoplastic polymers include (but arenot limited to) polypropylene, polyethylene, polystyrene, ABS(acrylonitrile-butadiene-styrene), nylon, polycarbonate, thermoplasticpolyester, polyphenylene oxide, polysulfone and PEEK(poly-ether-ether-ketone). Exemplary thermosetting polymers include (butare not limited to) unsaturated polyester, vinyl ester, epoxy, urethaneand phenolic.

The flooring material can also include polymer matrix composite (PMC)resin systems in which a reinforcing material, typically a fiber, isadded to the polymer resin to strengthen the finished part. Common fiberreinforcement materials include carbon/graphite, aramid, and glass. Eachof these can be present as yarns, rovings, chopped strands, and wovenand nonwoven fabrics.

The flooring material can also include polymer matrix composite resinsystems such as set forth in commonly owned pending U.S. ProvisionalApplication No. 60/942,488, filed Jun. 7, 2007, the entire disclosure ofwhich is hereby incorporated by reference. Exemplary polymer matrixcomposite resin systems in accordance with this embodiment of theinvention can include polyvinyl chloride polymer and polyester fibers.

The method of the invention can include the steps of forming each of thestep cuts (or angled edges as discussed below) along one or both edgesof a first sheet of polymer flooring material prior to the step ofjoining the sheets to one another. In one embodiment, the sheet materialis formed with complementary step edges (or angled edges) so thatregardless of orientation the step (or angled edge) on one edge alwaysfaces opposite from the step (or angled edge) on the other edge. FIG. 3illustrates this embodiment. This embodiment is also particularlyconvenient because it defines a single type of sheet that can always bejoined to an adjacent sheet of the same construction. Once the firstsheet is in place on the floor, the second identically oriented sheetcan always be flipped or turned as necessary to present thedownwardly-facing step cut (or angled edge) to an upwardly-facing stepcut (or angled edge).

Alternatively, the sheets can be formed to have identical step cuts (orangled edges) along each edge; i.e. both cuts oriented upwardly-facingor both cuts oriented downwardly-facing on any particular piece. Such astructure is also easy to use in the context of the present inventionbecause an individual sheet can again simply be flipped to place it inthe proper orientation for use adjacent to an existing sheet on thefloor. In both embodiments, the sheets can be quickly and easily placedside-by-side on the floor to produce the final flooring material.

FIG. 3 illustrates an alternative embodiment of the invention in whichat least one edge 27 of the sheet 21′ is oblique rather than verticalwith respect to the flooring surface. In practicing the invention, ithas been found that although a perfectly square step lap joint (FIG. 2B)is possible, in most circumstances using the slight oblique face 27produces a joint that is more flush at the surface because the extraspace created between the oblique face 27 and the second piece offlooring 20 is more forgiving or small misalignments or defects in theflooring material. An edge of riser 23 of sheet 20 of FIG. 3 can also beoblique rather than vertical with respect to the flooring surface inaddition to or as an alternative to oblique edge 27.

FIGS. 10A and 10B illustrate yet an alternative embodiment of anexemplary joint useful for joining polymer sheet materials in accordancewith the present invention. The joint is formed between respective firstand second portions 20″ and 21″ of the flooring material (such as PVCsheets). Each of the pieces 20″ and 21″ includes an angled (or beveled)end portion or edge 60 and 62, respectively. The degree of anglerelative to the flooring surface can vary and is typically greater than(or less than) 90 degrees, for examples, about 120 degrees, about 60degrees, about 45 degrees, and the like. When these pieces are broughttogether as illustrated in FIG. 10B, they form a joint broadlydesignated at 64. Accordingly, the present invention can also bedescribed in general terms of joining or bonding polymer sheet materialshaving overlapping end portions or edges (whether the ends overlap inthe form of a lap joint as illustrated in FIGS. 2A and 2B or as beveledor angled edges as illustrated in FIGS. 10A and 10B). The inventors havefound that overlapping the ends of the sheet materials can beadvantageous regardless of the specific shape of the overlapping ends orthe resultant joint.

As illustrated in FIGS. 5 and 7, heat is typically applied to therespective step faces in any fashion that raises the temperature to thedesired or necessary level without otherwise interfering with theflooring material or the floor. Thus, a tool 45 that produces andapplies hot air is particularly convenient because it can raise thetemperature of the polymer material to the necessary temperature withoutplacing any physical object in direct contact with the polymer. As aresult, the step cuts can be joined to one another in an efficientfashion.

Direct contact (conductive) heating devices can also be used, but in afashion that does not remove polymer material (i.e. by sticking to theheating device) or otherwise interfering with the flooring material orthe floor.

The present invention is not limited to hot air welding methods anddevices for installing the flooring. In accordance with variousalternative embodiments, the flooring can be installed using any weldingtechniques suitable for welding polymeric materials, including withoutlimitation ultrasonic, microwave or radio frequency (RF) treatmentmethods and/or devices capable of applying sufficient energy to weld orbond the respective pieces of the flooring materials.

RF welding can be particularly advantageous in various installationapplications. As will be appreciated by the skilled artisan, radiofrequency welding, sometimes known as RF, dielectric or high frequency(HF) welding, is a process of fusing materials together by applyingradio frequency energy to the area to be joined. The principle behindthe process is the use of high frequency radio energy to producemolecular agitation in thermoplastic materials (such as PVC), which cantranslate into thermal energy. The thermal energy can heat the materialsto a point at which the materials flow together on a molecular level,typically forming a bond that can be as strong as the original material.In the United States, the most common RF welding frequency is set at27.12 MHz, but frequencies can vary depending on country, and otherfrequencies can be employed in the invention as appropriate.

In various exemplary embodiments of the invention, the flooring piecescan be joined using RF welding. A bottom welding element made of amaterial suitable for use as an electrode for a RF system fortransferring electrical energy through the flooring pieces can bepositioned between a lower surface of the flooring pieces 20, 21 and anexposed surface of a subfloor to which the flooring pieces are to beinstalled (for example, aluminum foil positioned on the exposed surfaceof a concrete subfloor and/or a lower surface of pieces 20, 21).Generally, the bottom welding element remains in place between theflooring pieces 20, 21 and the subfloor onto which the flooring isinstalled after installation is complete. This embodiment of theinvention can also use additional components of a RF system, such as anupper welding element (also made of a material suitable for use as anelectrode for a RF system for transferring electrical energy through theflooring pieces) and RF power input components (such as a RF weldingenergy source, cabling, transducer, power regulator, and the like) forgenerating and transferring energy to the upper and lower weldingelements to join the step cuts to one another. Such components for RFwelding devices can be part of, for example, of a hand held or portableRF device of a suitable size and shape as appropriate for theinstallation of flooring, which the skilled artisan will appreciate andunderstand based on the disclosures herein without undueexperimentation.

In order to complete the sealing (or bonding) process, pressure can beapplied to the surface of the second sheet 21 above the downwardlyfacing step cut (or angled edge). This is illustrated in FIG. 5 in whichthe first sheet 20 and the second sheet 21 form the step lap joint 26 inthe described manner and a weighted roller 30 or equivalent device isused to apply pressure to enhance the joint 26.

FIG. 7 is entirely analogous to FIG. 5 but shows a new weld or repairbeing carried out in the manner illustrated in FIGS. 6C and 6D. As inthe first embodiment, the welding tool 45 applies heat to the flooringpieces 35 and 36, then the strip 37 is added (typically immediately)over the grooved portion, following which the roller 40 is used to applypressure (the combination of steps is typically a two-person task).

Both FIGS. 5 and 7 illustrate that all of the exposed edges of theflooring material pieces (20, 21, 35, 36) can be stepped in a mannerthat is amenable to producing a lap joint; i.e., in end-to-end fashionin addition to side-to-side fashion. It will be understood, of course,that phrases such as “end-to-end” and “side-to-side” are exemplary withrespect to rectangular flooring pieces, but do not otherwise limit theshape of the flooring that can be joined using the method of theinvention.

Accordingly, in a structural aspect, the invention is a floor coveringon a floor 19, with the floor covering comprising a first sheet 20 ofpolymer material with at least one upwardly facing step cut edge 24 (orangled edge) facing upwardly from the floor 19. A second sheet ofpolymer material 21 has at least one downwardly facing step cut edge 25(or angled edge) facing downwardly towards the floor 19 and immediatelyoverlies the upwardly facing step cut 24 on the first sheet 20. A seal(or bond) joins the upwardly facing step cut 24 to the downwardly facingstep cut 25 and thereby joins the first and second sheets 20, 21 ofpolymer material together on the floor 19.

As set forth with respect to the method embodiments, at least one (andpotentially both) of the first and second sheets 20, 21 is athermoplastic polymer. Alternatively, at least one (and potentiallyboth) of the first and second sheets 20, 21 can be a thermosettingpolymer. In one exemplary embodiment, the sheets 20, 21 are polyvinylchloride.

FIGS. 6A through 6D illustrate the method of the invention in a repaircontext. In this context, FIG. 6A illustrates a welded butt joint 33between respective flooring portions 35 and 36, and analogous to thejoint illustrated in FIG. 1, but with a crack 34 that weakens thestructure and the resulting integrity of the joint 33.

FIG. 6B illustrates the structure after the step of forming a step cutin the polymer flooring pieces 35 and 36 opposite both sides of theexisting butt joint 33.

FIGS. 6C and 6D illustrate the step of sealing a strap 37 of polymermaterial into the step cut 38 above the remainder of the butt joint 33to produce a combination strap and step lap joint broadly designated at40 that replaces the butt joint 33.

FIGS. 6A through 6D illustrate the step cut 38 formed in rectangularcross section with the steps parallel to the surface of the polymerflooring pieces 35 and 36. In the illustrated embodiment, the dimensionsof the polymer strap 37 correspond substantially to the dimensions ofthe step cut 38 to produce a repaired joint 40 in which the strap 37 andthe flooring material pieces 35 and 36 create a flush surface withrespect one another.

In a manner analogous to the first embodiment, the method can includethe step of applying pressure to the strap 37 and to the surface of thepolymer flooring material 35 and 36 to enhance the resulting joint. Thestrap 37 can be sealed (or bonded) to the step cut 38 with an adhesive,but in a manner analogous the previous embodiment, is typically heatsealed based upon the thermoplastic or thermosetting characteristics ofboth the polymer flooring pieces 35, 36 and the strap material 37.

In a structural context, FIGS. 6A through 6D illustrate a first sheet ofpolymer flooring material 35, a second sheet of polymer flooringmaterial 36 abutting the first sheet 35 along respective edges of eachsheet, and a partial butt joint 33 between the first and second sheets35, 36 adjacent the floor (19, FIG. 5). A channel illustrated as thestep cut 38 has portions that extend into the each of the first andsecond sheets 35, 36 above the partial butt joint 33. A polymer strap 37is positioned in the channel 38 above the partial butt joint 33, and issealed (integral with the structure and thus not illustrated separately)between and among the polymer strap 37, the first sheet of polymerflooring material 35 and the second sheet of polymer flooring material36. The resulting structure forms a combined strap and lap joint 40between and among the first sheet 35, the second sheet 36, and the strap37.

As in the other embodiments, the first and second sheets 35 and 36 andthe strap 37 are selected from among thermoplastic and thermosettingpolymers, typically including polyvinyl chloride, with the seal (orbond) being a heat seal between and among the sheets 35, 36 and thestrap 37. As illustrated in FIGS. 6C and 6D, in exemplary embodimentsthe polymer strap 37 has dimensions substantially the same as the stepcut channel 38 and as illustrated the channel 38 and the strap 37 arerectangular in cross section.

FIGS. 8 and 9 illustrate tools for welding plastic that are exemplary ofthose used in the present invention. FIG. 8 is a perspective view of ahot air tool 45 that can (depending upon the particular model) operateon 120 volt, 230 volt, or 1600 watt systems. The tool 45 can produce hotair at temperatures up between about 50 and 600° C. at airflow volumesof up to 200 liters per minute.

As illustrated, the tool 45 includes a handle 46, a power cord 47 ahousing 50, and a hot air tube 51. FIG. 8 also illustrates aconventional nozzle 52 used on the tool 45.

Representative tools are commercially available with one sourceincluding Leister direct, Bolton, United Kingdom (www.leister.co.uk).

FIG. 9 illustrates a modified nozzle broadly designated at 53 that hasbeen found useful in carrying out the method of the invention. Themodified nozzle 53 includes a female cup 54 for adapting to the tube 51.An elbow tube 55 directs the hot air away from the axis of the tool 45and through a narrow rectangular tip 56. This applies the hot air moreefficiently to the flooring material when carrying out the method of theinvention.

It will be understood that FIGS. 8 and 9 illustrate exemplaryembodiments of the tool 45 and the nozzle 53 and that other types of hotair welding tools and other nozzle geometries can be incorporated withinthe invention.

In the drawings and specification there has been set forth a preferredembodiment of the invention, and although specific terms have beenemployed, they are used in a generic and descriptive sense only and notfor purposes of limitation, the scope of the invention being defined inthe claims.

1. A method of installing flooring that is particularly useful forsanitary slip resistant applications such as kitchens, the methodcomprising: positioning a first sheet of polymer flooring material withan upwardly-facing step cut along one edge of the first sheet on a floorto be covered; and applying a second sheet of polymer flooring materialwith a complementary downwardly-facing step cut along one edge of thesecond sheet to the upwardly facing step cut of the first sheet and tothe floor adjacent the first sheet while concurrently bonding therespective faces to one another in a step lap joint using radiofrequency (RF) welding.
 2. A method according to claim 1 comprisingpositioning respective first and second sheets of thermoplastic materialon the floor and applying sufficient energy to the respective step facesto bond the polymer flooring material.
 3. A method according to claim 1comprising positioning respective first and second sheets ofthermosetting material on the floor and applying sufficient energy tothe respective step faces to bond the polymer flooring material.
 4. Amethod according to claim 1 comprising: forming a step cut along oneedge of a first sheet of thermoplastic polymer flooring material; andforming a complementary step cut along one edge of a second sheet ofthermoplastic polymer flooring material; both prior to the step ofpositioning the first sheet on a floor to be covered with the step cutfacing upwardly.
 5. A method according to claim 1 comprising applyingpressure to the surface of the second sheet above the downwardly facingstep cut to bond the respective step cuts to one another in a step lapjoint and thereby join the first and second sheets to one another.
 6. Amethod according to claim 2 comprising positioning sheets ofthermoplastic polymer that are selected from the group consisting ofpolyvinyl chloride, polypropylene, polyethylene, polystyrene, ABS(acrylonitrile-butadiene-styrene), nylon, polycarbonate, thermoplasticpolyester, polyphenylene oxide, polysulfone and PEEK(poly-ether-ether-ketone).
 7. A method according to claim 3 comprisingpositioning sheets of thermosetting polymer that are selected from thegroup consisting of unsaturated polyester, vinyl ester, epoxy, urethaneand phenolic.
 8. A method according to claim 3 comprising positioningsheets of a polymer matrix composite resin system that includesreinforcing fibers selected from the group consisting of carbon,graphite, aramid polymers, glass, and combinations thereof.
 9. A methodaccording to claim 2, comprising positioning sheets of a polymer matrixsystem that includes polyvinyl chloride and polyester fibers.
 10. Afloor covering on a floor, said floor covering comprising: a first sheetof polymer material with at least one upwardly-facing step cut edgefacing upwardly from the floor; a second sheet of polymer material withat least one downwardly-facing step cut edge facing downwardly towardsthe floor and immediately overlying the upwardly facing step cut of saidfirst sheet; and a bond formed by radio frequency (RF) welding joiningsaid upwardly-facing step cut to said downwardly-facing step cut andthereby joining said first and second sheets of polymer materialtogether all on said floor.
 11. A floor covering according to claim 10wherein at least one of said first and second sheets is a thermoplasticpolymer.
 12. A floor covering according to claim 11 wherein both of saidfirst and second sheets are thermoplastic polymers.
 13. A floor coveringaccording to claim 10 wherein at least one of said first and secondsheets is a thermosetting polymer.
 14. A floor covering according toclaim 13 wherein both of said first and second sheets are thermosettingpolymers.
 15. A floor covering according to claim 10 wherein said firstand second sheets are polyvinyl chloride.
 16. A floor covering accordingto claim 11 wherein said thermoplastic polymer is selected from thegroup consisting of polypropylene, polyethylene, polystyrene, ABS(acrylonitrile-butadiene-styrene), nylon, polycarbonate, thermoplasticpolyester, polyphenylene oxide, polysulfone and PEEK(poly-ether-ether-ketone).
 17. A floor covering according to claim 13wherein said thermosetting polymer is selected from the group consistingof unsaturated polyester, vinyl ester, epoxy, urethane and phenolic. 18.A floor covering according to claim 10 comprising a polymer matrixcomposite resin system that includes reinforcing fibers selected fromthe group consisting of carbon, graphite, aramid polymers, glass, andcombinations thereof.
 19. A floor covering according to claim 10 whereinsaid downwardly-facing step cut edge includes an oblique face adjacentthe top surface of said second sheet.
 20. A floor covering according toclaim 10, wherein at least one of said first and second sheets comprisesa polymer matrix system that includes polyvinyl chloride and polyesterfibers.
 21. A method of repairing a butt joint in polymer flooringmaterials comprising: forming a step cut in polymer flooring on bothadjacent sides of an existing butt joint; and bonding a strap of polymermaterial using radio frequency (RF) welding into the step cut above theremainder of the butt joint to produce a combination strap and step lapjoint to replace the butt joint.
 22. A portion of flooring material on afloor comprising: a first sheet of polymer flooring material; a secondsheet of polymer flooring material abutting said first sheet alongrespective edges of each sheet; a partial butt joint between said firstand second sheets adjacent the floor; a channel, portions of whichextend into each of said first and second sheets above said partial buttjoint; a polymer strap positioned in said channel above said partialbutt joint; and a bond between and among said polymer strap, said firstsheet of polymer flooring material and said second sheet of polymerflooring material formed by radio frequency (RF) welding that forms acombined strap and lap joint between and among said first sheet, saidsecond sheet, and said strap.
 23. A flooring element comprising: agenerally rectangular three-dimensional solid polymer in a thickness ofat least about one quarter inch, a width of at least about four feet anda length of at least about six feet; and an angled edge cut along eachlengthwise edge of said rectangular three-dimensional flooring element.24. A flooring element according to claim 23 wherein said polymer isselected from the group consisting of thermoplastic polymers,thermosetting polymers and polymer matrix composites.
 25. A flooringelement according to claim 24 comprising a thermoplastic polymerselected from the group consisting of polyvinyl chloride, polypropylene,polyethylene, polystyrene, ABS (acrylonitrile-butadiene-styrene), nylon,polycarbonate, thermoplastic polyester, polyphenylene oxide, polysulfoneand PEEK (poly-ether-ether-ketone).
 26. A flooring element according toclaim 24 comprising a thermosetting polymer selected from the groupconsisting of unsaturated polyester, vinyl ester, epoxy, urethane andphenolic.
 27. A flooring element according to claim 24 wherein saidflooring element comprises a polymer matrix composite that includesfibers selected from the group consisting of carbon, graphite, aramidpolymers, glass, and combinations thereof.
 28. A flooring elementaccording to claim 24 wherein said flooring element comprises a polymermatrix system that includes polyvinyl chloride and polyester fibers. 29.A method of installing flooring that is particularly useful for sanitaryslip resistant applications such as kitchens, the method comprising:positioning a first sheet of polymer flooring material with anupwardly-facing angled cut along one edge of the first sheet on a floorto be covered; and applying a second sheet of polymer flooring materialwith a complementary downwardly-facing angled cut along one edge of thesecond sheet to the upwardly facing angled cut of the first sheet and tothe floor adjacent the first sheet while concurrently bonding therespective faces to one another.
 30. A method according to claim 29comprising positioning respective first and second sheets ofthermoplastic material on the floor and applying sufficient energy tothe respective angled edges to bond the sheets.
 31. A method accordingto claim 29 comprising positioning respective first and second sheets ofthermosetting material on the floor and applying sufficient energy tothe respective angled edges to bond the sheets.
 32. A method accordingto claim 29, comprising bonding the respective faces of said first andsecond polymer sheets using radio frequency (RF) welding.
 33. A floorcovering on a floor, said floor covering comprising: a first sheet ofpolymer material with at least one upwardly-facing angled edge facingupwardly from the floor; a second sheet of polymer material with atleast one downwardly-facing angled edge facing downwardly towards thefloor and immediately overlying the upwardly facing angled edge of saidfirst sheet; and a bond joining said upwardly-facing angled edge to saiddownwardly-facing angled edge and thereby joining said first and secondsheets of polymer material together all on said floor.
 34. A floorcovering according to claim 33 wherein said bond is formed by radiofrequency (RF) welding.
 35. A method of installing flooring that isparticularly useful for sanitary slip resistant applications such askitchens, the method comprising: positioning a first sheet of polymerflooring material with an upwardly-facing cut along one edge of thefirst sheet on a floor to be covered; and applying a second sheet ofpolymer flooring material with a complementary downwardly-facing cutalong one edge of the second sheet to the upwardly facing cut of thefirst sheet and to the floor adjacent the first sheet while concurrentlybonding the respective faces to one another.
 36. A method according toclaim 35, comprising bonding the respective faces of said first andsecond polymer sheets using radio frequency (RF) welding.